Karmek KK IDRO Manual

PELLET BOILER
KK IDRO
OPERATING AND MAINTENANCE HANDBOOK

2
Dear Customer,
We want to thank You for choosing one of our production boilers for your purchase. We are
confident that we supplied You with a technologically valid product.
In the following pages, we provide You with some instructions, so that You may know and use the
product at its best, as well as ordinarily upkeep it.
Our authorized technical service remains at Your complete disposal for any necessity.
Best regards,
Karmek S.R.L.
PLEASE NOTE:
Karmek reserves itself to carry out unsubstantial changes to the boiler’s components, which may
not be reported in the present handbook, those being of small entity. Occasional appearance
changes from the flyers are due to ordinary seasonal updates.

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A. GENERAL INFORMATION
a.1 General safety rules
a.2 Technical features
a.3 Accessory equipment
a.4 Optional equipment
a.5 Identity plate
a.6 Guarantee
a.7 Suitable fuel
a.8 Ordering spares
B. INSTALLATION INSTRUCTIONS
b.1 Initial warnings
b.2 Moving and transporting
b.3 Positioning
b.4 Installing the flue gas outlet
b.5 Installing the combustion air inlet pipe
b.6 Connecting to the power supply
b.7 Connecting to the waterworks
C. OPERATING INSTRUCTIONS
c.1 Initial warnings
c.2 Presentation
c.3 Display
c.4 Lighting the boiler for the first time
c.5 Activating the boiler
c.6 Room temperature setting
c.7 Switching off the boiler
c.8 The remote control
c.9 Managing the automatic lighting (chronothermostat)
D. FUNCTIONS OF THE MECHANICAL AND ELECTRIC
COMPONENTS
d.1 Screw motor
d.2 Smoke intake motor
d.3 Safety thermostat
d.4 Electronic card

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d.5 General switch
d.6 Circulator
d.7 Expansion vessel
d.8 Transducer
d.9 Fumes probe
d.10 Room probe
d.11 Safety valve
d.12 Air valve
d.13 Sparking plug
d.14 Pressurestat
E. WASTE MATERIAL
F. ORDINARY CLEANING AND MAINTENANCE
f.1 Cleaning and maintenance by the customer
f.2 Periodic maintenance by the Assistance Center
G. ALARMS DISPLAYING
g.1 Fumes temperature probe alarm
g.2 Unsuccessful lighting alarm
g.3 Switching-off while working alarm
g.4 Power failure alarm
g.5 General thermostat alarm
g.6 Room thermocouple alarm
g.7 Circuit pressure alarm
H. SOLUTIONS TO POSSIBLE PROBLEMS

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A. GENERAL INFORMATION
a.1 General safety rules
ATTENTION PLEASE!!! You can never be too cautious: before the installation read and
comply with these fundamental Rules:
All local regulations, including those referring to national and European laws, must be
respected while installing the boiler.
Verify if the electrical system and the mains outlets are able to bear the maximum absorption of
the boiler, which is reported on the plate.
Connect the boiler to a norm-compliant, 230v – 50Hz mains outlet. Avoid using adapters,
multiple sockets or extensions.
Make sure the electrical system is provided with a norm-compliant earthing and differential
switch.
●In order to install the boiler you must respect the current laws regarding the exhausting through
the flue. It is advisable to connect the boiler to the flue by a terminal, which should be easy to
inspect. We remind you that it is necessary to refer to an authorized assistance center for the
installation and periodical maintenance of the boiler, so to check the efficiency of the flue
draught, before and after the combustion work of the boiler.
●The boiler consumes as much air as it is necessary for the combustion; it is thus advisable to
connect the boiler to the outside by a suitable piping, ending at the special slot on the back of
the boiler.
●Given the weight of the boiler, before the installation, make sure the pavement is able to bear it.
●If the pavement is made of inflammable material, such as parquet or carpeting, position a plate
under the boiler to protect it, (consider that, on the front of the boiler, the plate should exceed
the boiler by at least 25/30cm).
●For your safety, it is advisable to maintain a distance of at least 20cm between the hot sides of
the boiler and possibly inflammable covering materials (such as glass-beaded walls, wallpapers
et cetera); otherwise, to use specific insulating materials, available on sale. Please make this
consideration also regarding the furniture, armchairs, curtains and so on.
●In order to facilitate the possible interventions by the technical assistance, do not fit the boiler
inside closed spaces and do not place it adjacent to the walls, for this may compromise the

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correct afflux of the air.
●The lack of draught by the flue (or, for instance, the obstruction or closing of the air entrance of
the grate, or of the grate itself) alters the functioning of the boiler, which, while automatically
switching-on, may provoke an excessive pellet dosage in the grate, due to delayed fire priming.
Excessive smoke in the combustion chamber can cause an automatic priming of the fumes
(gas), accompanied by a violent flame; in these conditions, we recommend never opening the
combustion chamber door.
●Categorically avoid using inflammable liquids to start the fire; when the boiler is on, the pellet
lighting is automatic.
●The pellets feeding the boiler must necessarily present the characteristics described in this
handbook.
●Do not touch the glass when the boiler reaches its temperature; be cautious before touching the
boiler.
●Avoid letting children close to the boiler on their own, when it is on, because each hot surface
can provoke severe burns.
●Do not perform interventions on the boiler, apart from those expected for a regular functioning
or suggested in this handbook in order to solve slight problems. In any case, always unplug
the boiler from the power supply before an intervention, and operate solely when the
boiler is cold.
●It is absolutely forbidden to remove the guard protecting the pellet tank.
●In case an intervention to the waterworks is necessary, make sure that the boiler is off, that the
water afflux to the boiler is stopped and that the water already in the boiler is completely cooled.
●Always make sure and check for the combustion chamber door to be hermetically closed when
the boiler is lighting or functioning.
●The pellet automatic lighting is the most delicate phase; in order for it to take place without
inconveniences, we recommend always to keep the boiler and the grate clean.
If anomalies in the functioning should occur, light the boiler again only after fixing the problem
at its origin.
Karmek Srl is not responsible for inconveniences, tampering, breakages or any other damage
due to non-observance of the instructions reported in this handbook.

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a.2 Technical features
Nominal power:
24Kw
Nominal thermic power:
20Kw

conventional efficiency and room irradiating:
5Kw

H2o efficiency:
15Kw
Reduced thermic power:
9,7Kw

conventional efficiency and room irradiating:
2,2Kw

H2o efficiency:
7,5Kw
Efficiency:

at nominal thermic power:
82%

at reduced thermic power:
80,5%
Power supply:
230V 50Hz
Power absorption:
330W
Volumetric flaw of combustion gas

at nominal thermic power:
16,45g/s

at reduced thermic power:
13,59g/s
CO measured at 13% of oxygen:

at nominal thermic power:
0,039%

at reduced thermic power:
0,034%
Exhausted gas temperature:

at nominal thermic power:
300,3°C

at reduced thermic power:
205,4°C
Minimum requirements for the chimney’s draught at nominal thermic
power:
12Pa
Minimum req
uirements for the chimney’s draught at reduced thermic
power:
10Pa
Boiler capacity (H2o):
16Lt
Pellet tank capacity:
55Kg
Pellet consumption (Kg/h):
2
-
4,9Kg/h
Autonomy (min
-
max/h):
11
-
27
Digital control display:
YES
Weekly program:
YES
Room thermost
at:
YES
Manual
–
automatic functioning:
YES
System circulator:
Prev. 3,5m YES
Expansion vessel:
6Lt
Safety valve:
YES
Pressure transducer:
YES
Adjustable feet:
YES
Dimensions:
647x625x1288mm
Weight:
172Kg
Fuel:
pellet Ø6mm
Fumes joint:
Ø100mm
Ai
r inlet:
Ø50mm
Exercise pressure:
from 0.7 to 1.5bar
Minimum safety distance from inflammable materials:
200mm

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1-Combustion air intake
2-Flue connection
3-H2O Lock 3/4” radiator
4-1/2” Waterworks connection
5-Radiator return 3/4”
6-Power supply

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a.3 Accessory equipment
The boiler is equipped with:
- a remote control;
- a supply cable;
- adjustable feet;
- a handbook.
a.4 Optional equipment
External chronothermostat: the boiler is not equipped with this optional device, which is instead
installable according to the positioning of the boiler.
The aforementioned chronothermostat must be directly connected to the card (see the electric
scheme), in addition to the connections to the room probe.
IMPORTANT: in order for the chronothermostat to function correctly, you must exclude the room
temperature, bringing it to a 0.8°C value. The room temperature can then be directly regulated with
the chronothermostat.
a.5 Identity plate
The identity plate is positioned on the back of the boiler, and it reports the following data:
- commercial brand - supply tension
- serial number - absorbed electric supply
- model - nominal frequency
- thermal power - minimum distance from adjacent
- efficiency infiammable materials
- measured CO percentage - conformity to regulations
- exercise pressure - warnings.
a.6 Guarantee
The guarantee certificate, which we consigned to you when you purchased the boiler, must be sent
to the producer firm Karmek Srl, 8 days after delivery date the latest; otherwise, the guarantee
itself will no longer be valid. The estimated 24-months guarantee is valid exclusively when the
installation and test are performed by an authorized Karmek assistance center.
We would like to make clear that the guarantee expires in case of tampering, breakages, and
similar, due to non-observance of the instructions reported in this handbook.

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a.7 Suitable fuel
The boiler functions solely by pellets, a cylinder-shaped fuel made out of a mixture of various
wooden materials; pellets are compliant to DIN 51731 regulations.
The following list summarizes the main characteristics of recommended pellet:
Diameter
6
-
6,5mm
Maximum length
20
-
25mm
Caloric output
Approx. 4.600 Kcal/Kg
Humidity
<12%
Ash content
<1,5%
Specific weight and density
Kg/dm
³
=1,0
-
1,4
The boiler is built to burn not-resinous, preferably beech-wood pellets; therefore, using pellets
whose characteristics are different from the ones listed above reduces its efficiency, provokes a
bad combustion and the formation of incrustations.
Should you use different pellets from the ones recommended the boiler’s guarantee would expire.
a.7 Ordering spares
Exclusively authorized Karmek technical personnel must perform interventions of any entity.
Please refer to the authorized assistance center or to your retailer for possible requests of spares.

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B. INSTALLATION INSTRUCTIONS
b.1 Initial warnings
The device must be installed on a pavement that presents an adequate burden capacity. If the
existing building does not satisfy this requirement, appropriate measures (for instance a burden
distribution plate) must be taken.
The installation of the device must guarantee an easy access to clean the boiler, the exhausted
gas piping and the flue.
Extraction fans can cause problems, when used in the same room or space of the device.
b.2 Moving and transporting
Make sure that the devised used for lifting and transporting the boiler support its weight, which is
reported on the identity plate on the back of the boiler. The lifting of the boiler is normally
performed with an elevation trolley, by inserting the pitchforks in the proper slots of the wooden
packing. In order to position the boiler inside a room, a good general rule is to lay the boiler on the
floor gently, with maximum caution and avoiding any violent impact.
b.3 Positioning
For positioning the boiler, we suggest you to choose a spot that is as central as possible to the
area you wish to heat; this will facilitate a uniform distribution of the heat and will help obtaining an
optimum efficiency.
In order to connect the boiler to the waterworks, a performance by a qualified technician or
plumber is necessary. We recommend putting a floor-guarding plate close to the flue or to
inflammable materials (such as parquet or carpeting).
For safety reasons, maintain a distance of at least 20cm
between the hot sides of the boiler and possibly inflammable
covering materials (such as glass-beaded walls, wallpapers
et cetera); otherwise, use specific insulating materials,
available on sale.
L=20 cm min. B=20 cm min. R=20 cm min.

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b.4 Installing the flue gas outlet
The installation can be performed either without a masonry flue, or with an existing flue.
FIG 1. INSTALLATION WITHOUT A MASONRY FLUE
Flue gas outlet Ø 100 – Using an easy to inspect T-joint, reach the outside of the building
horizontally; proceed vertically until you reach the roof with a cohibented flue, equipped with an
anti-wind chimneystack. All the joints must be sealed.
FIG. 2. INSTALLATION WITH AN EXISTING FLUE
Flue gas outlet Ø 100 – Reach the existing flue horizontally, making sure that it presents a
minimum section of 200cm² and an easy to inspect base, for its annual cleaning. All the joints must
be sealed.
IMPORTANT!! We recommend you to have the installing technician verify the efficiency and the
state of the flue, the observance of national and local laws regarding flue gas outlets’ joints, and to
use appropriate materials.
The information reported above is purely indicative for a correct installation; Karmek Srl is not
responsible for what concerns the installation.

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Ø 100 Ø 100

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b.5 Installing the combustion air inlet pipe
For any described solution, two alternatives are possible:
●Draw the air directly from the outside through a piping (internal Ø 50mm; max length 1,5m),
connected to the air inlet pipe on the back of the boiler.
●Draw the air directly from the installation room, given that in the proximity of the boiler an air
inlet pipe (minimum area 100 cm²) is installed on the sidewall, so that it communicates with the
outside.
In both cases, periodically verify that nothing has obstructed the passage of the air.
IMPORTANT: This device cannot be used on a shared flue.
b.6 Connecting to the power supply
Verify if the electrical system and the mains outlets present the capacity to support the maximum
absorption of the boiler, which is reported on the plate.
Make sure the system is provided with a norm-compliant earthing and differential switch.
The boiler must be connected to a norm-compliant, 230v – 50Hz mains outlet. Avoid using
adapters, multiple sockets or extensions.
Make sure the cable connecting to the system is not touching any hot surface of the boiler; also
make sure the boiler is not treading on the cable.
The engine of the boiler is protected by a fuse, which is inserted in the general switch on the back
of the boiler.
Remember always to unplug the boiler from the power supply before performing any maintenance
and/or control intervention.

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ELECTRICAL SCHEME

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b.7 Connecting to the waterworks
The pellet boiler is equipped with a heating water circuit, completed of circulator, safety valve,
temperature probe and pressurestat. The heating circuit can be connected directly to the system
(radiators and other exchangers), without any additional components.
When connecting the boiler with the waterworks, you must be make sure that the equipped joints
are compatible with those of the system; otherwise, perform the connection with suitable joints.
Connect the boiler correctly, as shown in the picture (see below).
In order to avoid malfunctioning or damages to the boiler, qualified personnel must perform the
connection to the waterworks.

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C. OPERATING INSTRUCTIONS
c.1 Initial warnings
All regulations, included those referring to national and European laws, must be respected when
installing the device.
Do not use the device as an incinerator or in any other way than that for which it was designed.
Do not use any fuel other than pellets.
Do not use liquid fuels.
The device, and its external surfaces specifically, reach an elevate temperature when working;
handle with care to avoid burns.
Do not perform any unauthorized alteration to the device.
Only use original spares, recommended by the building firm.
c.2 Introduction
The pellet boiler combines the heat of a flame with the comfort of an automatic management of the
temperature, of the lighting and the switching-off, with the possibility of a multiple days
programming. The automatic loading and the consistent capacity of the tank allow the pellet boiler
to perform automatically for a longer time, and they permit a better management of the device.
If the boiler reaches a temperature of 60°C inside the thermo chamber, it activates the provided
system circulator, permitting the diffusion of the heat inside the building. The lighting temperature
of the circulator can be modified. If the boiler exceeds by 10°C the set value and the temperature
keeps constant for a certain amount of time (defined by the building firm), the device will not
furthermore feed the flame. When the fumes’ temperature falls at a value defined by the building
firm, the boiler will automatically light the flame up again.
The boiler must always function with its door peremptorily closed.
It is necessary that outlet system of the flue gas be properly sealed.
To ensure a good efficiency and a correct functioning, it is necessary that the boiler is always
clean.

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c.3 Display
In the following scheme, we report the various functions of the display.
IMPORTANT: If the temperature is not set within a few seconds, the display will automatically
return to the previous screenshot.

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c.4 Lighting the boiler for the first time
A skilled technician must perform the first lighting; otherwise, the guarantee will expire.
c.5 Activating the boiler
When the pellet tank is filled for the first time, you must remember that the screw tube, which feeds
the grate, is completely empty; therefore, when you light the boiler for the first time you must
manually insert the pellets and light the boiler.
Press the key n. 4 “ON/OFF” until the message “FAN CARD” appears on the display.
While lighting, the boiler begins pre-heating the resistance for approximately 1 minute.
After the pre-heating, the message “LOAD WOOD” appears; this means that the screw is loading
the pellets at a speed, which is defined by the technical settings (which can be modified).
The fuel loaded in the grate meets the incandescent resistance and will burn, provoking the
beginning of the combustion.
When the switchboard infers through the probe that the temperature is high enough, the boiler is
brought to the control mode, which will make the message “FIRE ON” appear on the display. In the
while, the pellet supply is increased to raise the temperature even higher, with a defined gradient
(approximately 3°C per minute).
When the pellets inside the grate are completely burned, the boiler proceeds in its normal
functioning.
The water pressure for the lighting of the boiler goes from o.5 to 1.5bars. It is possible to display
the internal pressure of to the system by pressing the key n. 2 for a few seconds.
c.6 Room temperature setting
The boiler is equipped of a thermostat with a room temperature survey probe, which is located on
the back. Its use permits to stabilize and maintain the temperature in the room where it is situated.
To modify the room temperature it is sufficient to push the key n. 3 “SET” for a while, then to
regulate the increase and decrease of the temperature with the keys n. 1 and 2.
IMPORTANT:
WHEN THE ROOM TEMPERATURE IS REACHED, THE BOILER AUTOMATICALLY
MODULATES THE PELLET SUPPLYING BY USING THE NECESSARY FUEL TO MAINTAIN
THE SET TEMPERATURE (“RIS” MODE).

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c.7 Switching off the boiler
You can switch the boiler off by pushing the key n. 4 for a few seconds. The message “OFF” will
appear on the display; the pellet flow is interrupted and the speed of the smoke intake motor will
increase to lower the temperature. The boiler will complete its cycle and will switch off
automatically.
In case of involuntary switching off, it is sufficient to push the key n. 6 for approximately 2 seconds.
This operation will immediately restart the working phase “ON”; the complete lighting phase can be
spared if the temperature of the fumes is higher than 50°-60°.
c.8 The remote control
The provided remote control permits to perform the following functions:
- to light and to switch off the boiler:
point the remote control while pushing the upper keys, marked by the symbol “+”
- to vary the power of the flame:
push the “+” and “-“keys marked by the fire symbol
- to regulate the room temperature:
push the “+” and “-“keys marked by the thermometer symbol